DEFORMATION ANALYSIS OF SHEET METAL SINGLE-POINT INCREMENTAL FORMING BY FINITE ELEMENT METHOD SIMULATION

Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.

PREDICTION FOR FORMING LIMIT OF AL2024T3 SHEET BASED ON DAMAGE THEORY USING FINITE ELEMENT METHOD

This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite element cell model has been constructed. The cell model consists of two phases, the aluminum alloy matrix and the intermetallic cluster. The material behavior of the aluminum alloy matrix is described with a fully coupled elasto-plastic damage constitutive equation. The intermetallic cluster is assumed to be elastic and brittle. By varying the stretching ratio, the limiting strains of the sheet under biaxial stretching have been predicted by using the necking criterion proposed. The prediction is in good agreement with the experimental findings. Moreover, the finite element cell model can provide information for understanding the microscopic damage mechanism of the aluminum alloy. Over-estimation of the limit strains may result if the effect of material damage is ignored in the sheet metal forming study.

Finite element method simulation of shotpeening wing skin panel

Finite element method(FEM) was used to simulate the forming process of shotpeening the wing skin panel. Experiment of shotpeeing the wing skin panel was carried out. The results show that equivalent deformation in shotpeening process can be obtained using the elongation and bending result caused by thermal stress that is induced by applying temperature load on the surface of the part. Deformation of the part in the shotpeeing process can be analyzed using this method. The parameters and their relationships are identified.

Analysis of Metal Forming in Two-Roll Cross Wedge Rolling Process Using Finite Element Method

A simulation model for two-roll cross wedge rolling （CWR） was presented by using three-dimensional rigid-plastic finite element method （FEM）. The whole forming process of CWR, including knifing zone, guiding zone, stretching zone, and sizing zone, was simulated using the model in which dynamic adaptive remeshing technology for tetrahedral solid elements was used to fix element distortion. Based on the simulation results, the distributions of metal flow field, strain field, and damage field, and the geometry of the workpiece＇s end were analyzed. These results could provide theoretical guidance for realizing net shaping and reasonable design of tools.

Simulation of bulk metal forming processes using one-step finite element approach based on deformation theory of plasticity

The bulk metal forming processes were simulated by using a one-step finite element(FE)approach based on deformation theory of plasticity,which enables rapid prediction of final workpiece configurations and stress/strain distributions.This approach was implemented to minimize the approximated plastic potential energy derived from the total plastic work and the equivalent external work in static equilibrium,for incompressibly rigid-plastic materials,by FE calculation based on the extremum work principle.The one-step forward simulations of compression and rolling processes were presented as examples,and the results were compared with those obtained by classical incremental FE simulation to verify the feasibility and validity of the proposed method.

Numerical analysis of coupled finite element with element-free Galerkin in sheet flexible-die forming

A numerical method for coupled deformation between sheet metal and flexible-die was proposed. Based on the updated Lagrangian （UL） formulation, the elastoplastic deformation of sheet metal was analyzed with finite element method （FEM） and the bulk deformation of flexible-die was analyzed with element-free Galerkin method （EFGM）. The frictional contact between sheet metal and flexible-die was treated by the penalty function method. The sheet elastic flexible-die bulging process was analyzed with the FEM-EFGM program for coupled deformation between sheet metal and bulk flexible-die, called CDSB-FEM-EFGM for short. Compared with finite element code DEFORM-2D and experiment results, the CDSB-FEM-EFGM program is feasible. This method provides a suitable numerical method to analyze sheet flexible-die forming.

Finite Element Simulation of Flexible Roll Forming with Supplemented Material Data and the Experimental Verification

Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.

A WEAK GALERKIN FINITE ELEMENT METHOD FOR THE LINEAR ELASTICITY PROBLEM IN MIXED FORM

In this paper, we use the weak Galerkin （WG） finite element method to solve the mixed form linear elasticity problem. In the mixed form, we get the discrete of proximation of the stress tensor and the displacement field. For the WG methods, we define the weak function and the weak differential operator in an optimal polynomial approximation spaces. The optimal error estimates are given and numerical results are presented to demonstrate the efficiency and the accuracy of the weak Galerkin finite element method.

The smoothed finite element method (S-FEM):A framework for the design of numerical models for desired solutions

The smoothed finite element method (S-FEM) was originated by G R Liu by combining some meshfree techniques with the well-established standard finite element method (FEM). It has a family of models carefully designed with innovative types of smoothing domains. These models are found having a number of important and theoretically profound properties. This article first provides a concise and easy-to-follow presentation of key formulations used in the S-FEM. A number of important properties and unique features of S-FEM models are discussed in detail, including 1) theoretically proven softening effects;2) upper-bound solutions;3) accurate solutions and higher convergence rates;4) insensitivity to mesh distortion;5) Jacobian?free;6) volumetric-locking-free;and most importantly 7) working well with triangular and tetrahedral meshes that can be automatically generated. The S-FEM is thus ideal for automation in computations and adaptive analyses, and hence has profound impact on Al-assisted modeling and simulation. Most importantly, one can now purposely design an S-FEM model to obtain solutions with special properties as wish, meaning that S-FEM offers a framework for design numerical models with desired properties. This novel concept of numerical model demand may drastically change the landscape of modeling and simulation. Future directions of research are also provided.

Finite element simulation of aluminum alloy cross valve forming by multi-way loading

Deformation behavior,temperature evolution and coupled effects have a significant influence on forming process and quality of component formed,which are very complex in forming process of aluminum alloy 7075 cross valve under multi-way loading due to the complexity of loading path and the multiplicity of associated processing parameters.A model of the process was developed under DFEORM-3D environment based on the coupled thermo-mechanical finite element method.The comparison between two process models,the conventional isothermal process model and the non-isothermal process model developed in this study,was carried out,and the results indicate that the thermal events play an important role in the aluminum alloy forming process under multi-way loading.The distributions and evolutions of the temperature field and strain filed are obtained by non-isothermal process simulation.The plastic zone and its extension in forming process of cross valve were analyzed.The results may provide guidelines for the determination of multi-way loading forming scheme and loading conditions of the forming cross valve components.

Theory and Method of Optimum Path Forming for Sheet Metal

Ideal forming results will be achieved if the sheet metal is formed along an optimum forming path. Such a path can be realized by multi-point forming technique. On the basis of the theory of the ideal forming path (or minimum plastic work path), the concept of an optimum forming path is proposed in this paper. The forming path can be described by the initial configuration, objective configuration and a series of intermediate configurations. According to the deformation theory and constitutive equation in ideal path forming, a finite element method to calculate the initial configuration is set up. The functional to determinate intermediate configurations is introduced and the numerical method to solve the configuration is presented. Based on the method presented in the paper, multi-step multi-point forming tests for sheet metal are designed. The test results demonstrate that when the sheet is deformed along an approximate optimum forming path, the maximum deformation curvature for the sphere objective shape and saddle objective shape are 11%∼40% and 15%∼50% greater than those of a sheet deformed along a common path respectively.

Three Dimension Rigid-plastic Finite Element Simulation for Two-Roll Cross-wedge Rolling Process

Cross-wedge rolling (CWR) is a metal process of ro ta ry forming. To produce a part, one cylindrical billet should be placed between t wo counterrotating and wedge-shape dies, which move tangentially relative each other. The billet suffers plastic deformation (essentially, localized compressio n) during its rotation between the rotating dies. Compared to other numerical si mulation methods, the finite element method (FEM) has advantages in solving gene ral problems with complex shapes of the formed parts. In cross-wedge rolling, t here are four stages in the workpiece deformation process, namely knifing, guidi ng, stretching and sizing stage. It is time-consuming and expensive to design t he CWR process by trial and error method. The application of numerical simul ation for the CWR process will help engineers to efficiently improve the process development. Tselikov, Hayama, Jain and Kobayashi, and Higashimo applied the sl ip-line theory in study of CWR process analysis. Zb.pater studied CWR process i ncluding upsetting by upper-bound method. The above numerical simulation were b ased on the two-dimensional plain-strain assumption ignored the metal flow in workpiece axial direction. Therefore, the complex three-dimensional stress and deformation involved in CWR processes were not presented. Compared to other nume rical simulation methods, the finite element method (FEM) has advantages in solv ing general problems with complex shapes of the formed parts. As yet, a few 3-D finite element simulation studies on CWR process have been reported in literatu res. In this paper, the process of cross wedge rolling (CWR) has been simulated and analyzed by 3D rigid-plastic finite element method. Considering the charact eristic of CWR, the static implicit FEM program is selected. The models proposed in this study uses the commercial code DEFORM 3D to simulate the CWR process. T his is an implicit Lagrangian finite element code, which includes many new enhan cements functions. A new method of utilizing multiple processors using the MPI s tandard has been implemented. Automatic switching between the two different defo rmation solvers (Sparse Solver and Conjugate Gradient Solver) has also been impl emented in order to increase the speed of simulations. In this paper, all stages in CWR process are simulated to be able to closely understand and analyze the a ctual CWR process. For simulating all forming stages in CWR process, the dynam ic adaptive remeshing technology for tetrahedral solid elements was applied. T he stress distributions in cross section of forming workpiece are analyzed to in terpret fracture or rarefaction in the center of workpiece. Authors also analyze d the time-torque curve and the laws of load changing.

Meshfree Method Numerical Simulation of Sheet Metal Forming Process

Metal forming plays an important role in manufacturing industry and is widely applied in industries.The tradi- tional finite element method(FEM)numerical simulation is commonly used to predict metal forming process.Conventional finite element analysis of metal forming processes often breaks down due to severe mesh distortion,therefore time-consuming remeshing is necessary.Meshfree methods have been developed since 1977 and can avoid this problem.This new generation of computational methods reduces time-consuming model generation and refinement effort,and its shape function has higher order connectivity than FEM’s.In this paper the velocity shape functions are developed from a reproducing kernel approximation that satisfies consistency conditions and is used to analyze metal tension rigid viscoplastic deforming and Magnesium Alloy(MB 15)sheet superplastic ten- sion forming.A meshfree method metal forming modeling program is set up,the partition of unity method is used to compute the integrations in weak form equations and penalty method is used to impose the essential boundary condition exactly.Metal forming examples,such as sheet metal superplastic tension forming and metal rigid viscoplastic tension forming,are analyzed to demon- strate the performance of mesh free method.

Springback prediction for incremental sheet forming based on FEM-PSONN technology

In the incremental sheet forming （ISF） process, springback is a very important factor that affects the quality of parts. Predicting and controlling springback accurately is essential for the design of the toolpath for ISF. A three-dimensional elasto-plastic finite element model （FEM） was developed to simulate the process and the simulated results were compared with those from the experiment. The springback angle was found to be in accordance with the experimental result, proving the FEM to be effective. A coupled artificial neural networks （ANN） and finite element method technique was developed to simulate and predict springback responses to changes in the processing parameters. A particle swarm optimization （PSO） algorithm was used to optimize the weights and thresholds of the neural network model. The neural network was trained using available FEM simulation data. The results showed that a more accurate prediction of s!oringback can be acquired using the FEM-PSONN model.

Sheet Metal Forming Simulation and Its Application in Stamping Process of Automobile Panels

The paper starts with a brief overview to the necessity of sheet metal forming simulation and the complexity of automobile panel forming, then leads to finite element analysis (FEA) which is a powerful simulation tool for analyzing complex three-dimensional sheet metal forming problems. The theory and features of the dynamic explicit finite element methods are introduced and the available various commercial finite element method codes used for sheet metal forming simulation in the world are discussed,and the civil and international status quo of automobile panel simulation as well. The front door outer panel of one certain new automobile is regarded as one example that the dynamic explicit FEM code Dynaform is used for the simulation of the front door outer panel forming process. Process defects such as ruptures are predicted. The improving methods can be given according to the simulation results. Foreground of sheet metal forming simulation is outlined.

广义弱形式自由单元法

自由单元法(FrEM)是一种单元配点法,吸收了有限元法等参单元的插值稳定性与无网格法使用灵活的优点,具有稳定性好和灵活性高的性能.FrEM在每个配置点只需要一个通过自由选择周围节点而形成的独立的等参单元,不需要考虑单元之间节点的相互连接关系,这种自由性使得人们可以按照学科性质形成所需要的单元,因而FrEM既适用于固体力学,也适用于流体力学问题的求解.然而,FrEM所用单元需要至少有一个内部节点(用于方程的配点),以致有限元法中单元节点相连的网格不能在FrEM中直接使用.文章基于对应于配置点的等参单元形函数在与其不相连的边界上为0的特性和配置点等效节点力平衡关系,提出了一种广义弱形式自由单元法(GFrEM).该方法是一种使用单元逐点建立配置方程的单元配点法,具有如下特点:(1)突破了现有自由单元法中单元需要内部节点的限制,因而可以使用线性单元和高阶单元;(2)突破了现有自由单元法中一个配置点使用一个单元的限制,可以使用与配置点相连的任意多个单元;(3)可以使用任意形式的规则单元和多边形/多面体单元;(4)如果使用单元节点相连的传统有限元法网格,则GFrEM自然演变为传统的有限元法.论文将给出几个固体力学方面的应用算例,展示所提方法的有效性.

个性化头部生物力学模型的开发及验证

本文提出了一种个性化头部生物力学模型建模方法,并对所生成模型进行了有效性验证。该方法以图斯特50th百分位头部生物力学模型为基础,基于目标模型头部CT数据,采用三维点云配准和自由网格变形法,实现具有详实脑组织结构的个性化头部生物力学模型的快速建模。通过重构经典尸体试验,发现该方法构建的个性化头部生物力学模型在运动学和生物力学响应方面与尸体试验结果高度一致,且与通过逆向工程方法开发的头部生物力学模型并无明显差异,验证了本文方法所开发模型的有效性。因此,本文方法可用于快速构建具有详细解剖学结构的个性化头部生物力学模型,为损伤生物力学、临床医学和法医鉴定等领域的数字化需求提供基础计算分析工具。

内孤立波作用下缓波形立管动力特性研究

我国南海活跃着大量内孤立波,严重威胁海洋工程作业的安全。本文采用向量式有限元方法分析内孤立波作用下深海缓波形钢悬链立管动力特性,建立考虑触地段土反力和内孤立波载荷的缓波形钢悬链立管动力模型,根据mKdV方程求解内孤立波载荷,基于向量式有限元梁单元编制Fortran计算程序。分析不同入射角内孤立波作用下立管的位移极值、张力及弯矩变化趋势,并比较缓波形立管与简单钢悬链立管在内孤立波作用下的动力特性。结果表明:内孤立波作用下,缓波形钢悬链立管会有较大的位移响应,特别是顶部悬垂段会有较大的水平位移;缓波形立管比简单钢悬链立管有更显著的张力变化幅值,有更加复杂的弯矩变化趋势。

2205/X65爆炸焊复合板JCO成型过程协同变形行为研究

为了研究JCO成型工艺参数对2205/X65爆炸复合板结合界面附近应变协调性的影响,建立了2205/X65爆炸复合板三点弯曲过程的有限元模型,结合数字图像相关法对模型进行了验证。采用该模型进行仿真研究,结果表明,上模半径越小,界面附近的最大应变差越大,复合板JCO在成型过程中变形不协调区域的宽度越小;跨距越小,复合板在JCO成型过程中变形不协调区域的宽度越大,跨度变化对界面附近最大应变差没有显著影响;下压量增大时,界面附近变形不协调区域的宽度增大,但界面附近最大应变差的变化不显著;下模半径大小和复合板厚度比对加工变形协调性影响不显著。在实际生产中,建议选用较大上模半径和较大跨距,采用小下压量多次成型。

T型截面铝合金型材零件成组加工技术研究与应用

针对目前飞机T型材零件单件弯曲成形效率低成形精确差的问题,提出了T型材弯曲件成组拉弯成形的成组加工方法。基于截面尺寸、引导线的曲率半径等信息建立了成组分析算法,对T型材进行分组,使用长型材拉弯成形后切割分段得到符合精确外形要求的T型材零件。通过理论计算、模拟分析和拉弯试验,验证了T型材拉弯成形成组加工技术的可行性,该方法提高了零件的制造效率和成形精度,可以大幅度降低人工矫正的工作量和加工成本。